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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 687 (Engine Emission Control - 3.0L Power Stroke Diesel) >> General Procedures >> Exhaust Gas Recirculation (EGR) Cooler Leak Test

Exhaust Gas Recirculation (EGR) Cooler Leak Test

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Special Tool(s) / General Equipment 

GFD557924Courtesy of FORD MOTOR COMPANY
 303-1511Tester, EGR Cooler Pressure

Leak detection 

  1. NOTE: Visually inspect for evidence of a coolant leak before performing the off-vehicle test.

    Remove the Exhaust Gas Recirculation (EGR) Cooler. Refer to: Exhaust Gas Recirculation (EGR) Cooler .

  2. Install the EGR Cooler Pressure Tester on the EGR cooler. Tighten the bolts. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.

    Torque

    : 89 lb.in (10 Nm)

    GFD557925Courtesy of FORD MOTOR COMPANY
  3. NOTE: Do not apply an unregulated air supply to the EGR cooler or exceed 248 kPa (36 psi) at any time, excessive pressure can damage the EGR cooler assembly.

    1. Adjust the EGR Cooler Pressure Tester air pressure regulator to the lowest setting.
    2. Close the EGR Cooler Pressure Tester air supply shutoff valve.
    3. Connect the regulated air supply to the EGR Cooler Pressure Tester.
    4. Open the EGR Cooler Pressure Tester air supply shutoff valve.
    5. Slowly adjust the EGR Cooler Pressure Tester air pressure regulator until 248 kPa (36 psi) is reached.
    6. Close the EGR Cooler Pressure Tester air supply shutoff valve. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.

    GFD557926Courtesy of FORD MOTOR COMPANY
    • Observe the EGR Cooler pressure gauge, there should be no more than 13.8 kPa (2 psi) drop over a 5 minute period.

    • If pressure loss is greater than 13.8 kPa (2 psi) go to step 5.

    • If pressure loss is less than 13.8 kPa (2 psi) go to step 6. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.

    GFD557927Courtesy of FORD MOTOR COMPANY
  5. NOTE: Do not submerge the EGR cooler assembly in water or damage to EGR valve will occur.

    Using a soap/water solution, test around the EGR Cooler test equipment. Repair as needed. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.

    GFD557928Courtesy of FORD MOTOR COMPANY
  6. If pressure decay greater than 2 psig in 180 seconds is observed, spray soapy water to sealed joints between EGR valve, EGR cooler bypass and EGR cooler shell to identify source of leak. Using a soap/water solution, test the EGR valve-to-bypass gasket, all the way around the EGR valve.
    GFD557929Courtesy of FORD MOTOR COMPANY
  7. If pressure decay greater than 2 psig in 180 seconds is observed, spray soapy water to sealed joints between EGR valve, EGR cooler bypass and EGR cooler shell to identify source of leak. Using a soap/water solution, test the gasket joints on both sides of the bypass-to-cooler core gasket, all the way around the bypass.
    GFD557930Courtesy of FORD MOTOR COMPANY
  8. If no staining is found, then go to step 9. Refer to: Exhaust Gas Recirculation (EGR) Cooler .
  9. If no external leaks are found but leak test still fails, replace EGR cooler. Refer to: Exhaust Gas Recirculation (EGR) Cooler .
  10. If no leaks are detected from the test, then return the EGR cooler assembly to service. Refer to: Exhaust Gas Recirculation (EGR) Cooler .
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